Ongoing consolidation of magnets Davide Tommasini on behalf

Ongoing consolidation of magnets Davide Tommasini on behalf of the Norma Team Ø What I will not detail further Ø What we did last year Ø The importance of spares Ø Status of spares Ø What still needs more understanding Ø What we are going to do Ø What may be needed to do after understanding Ø What is needed now Ø Importance of the yearly shut-down ØPSB energy increase Ø NORMAWEB Ø Conclusions Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What I will not detail further Recent reports: Ø Present Status of the PS Magnets: IEFC 07 -08 -2009 Ø Urgent spares: integrated in P. Strubin EDMS 1020624 Ø Review of Resistive Magnets Situation : IEFC 13 -11 -2009 Ø Status of resistive magnets in the LHC injectors chain: MT-21, Hefei, China Ø Quality Assurance for Normal Conducting Magnets: IEFC 22 -01 -2010 Ø The PS Booster, PS and SPS Magnets for the next 25 years : EDMS 1057909 Engagement of resources for a regular maintenance plan: Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What we did last year/are completing Ø Piquet service, 24 h/24, 7 d/7 Ø Comprehensive magnet inventory, naming and labeling Ø List of missing spares Ø Completed the consolidation program of the PS (51+4 magnets) Ø Completed the consolidation program of the SPS Lintott (254 magnets) Ø Replacement of all main water hoses in the PSB Ø Replacement of all main water hoses in the AD (under way) Ø Reorganization of the magnet workshops (181 -290 -867) Ø Many, many inspections and dedicated checks, at every machine technical stop Ø Two major interventions during operation: one in the PS and one in the SPS Ø Installation of flow meters in the LHC magnets Ø Reconstruction and certification of magnets for all machines Ø Fix the problem of missing spare NEA splitters Ø Finalized the French contribution to provide 30 sets of PFWs for the PS main units Ø AD consolidation, with approved manufacture of several spare magnets (under way) Ø Home made spares, as the correctors for Linac 2 and for Linac 3 Ø Assessment of North Experimental Area status Ø Validation of fix for the de-bonding of yoke laminations in the PS main units Ø From last year, each individual intervention is tracked and documented (QA) Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Major events during the 2009 run Magnet failures during the year 2009 produced, in total, 83 hours of machine down-time. The main failures were : • a short circuit of the magnet bus bars in the PS • a coil inter-turn short circuit in a SPS main dipole In total only 5 of these failures stopped machine operation An exercise Reference year of operation 2009 Number of magnets 3000 Number of failures 5 Machine down-time [hours] 83 MTTR [hours] 17 MTBF [years of operation] 600 Statistically we may be happy … or not ? Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

How does it compare FNAL Reference year of operation Number of magnets Number of failures 1999 -2006 1472 5 Machine down-time [hours] 83 MTTR [hours] 17 MTBF [years of operation] 600 SLAC Reference year of operation Number of magnets Number of failures Machine down-time [hours] MTTR [hours] MTBF [years of operation] Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Fault to ground of PS bus bar #22 -23 Incident Insulation failure to ground and between two bus bars, induced by a water leak from a cooling pipe Temporary fix Removal of the adjacent ground shield and wrapping of the bus bars in insulating sheets (polyimide) Definitive fix Was performed during a technical stop by replacing the defective bus-bar with a reinforced spare one Warning : we are missing two types of spare bus bar s ! Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

The importance of spares Two functions: Ø replace defective magnets Ø allow routine checks we need enough spares for affording both tasks how many ? Most faults can be repaired, except: Ø coil inter-turn short circuits Ø too radioactive magnets/components the number of spares, at least one, depends on: • regular maintenance plan (ex : SPS) • the HV test policy (no spares → no tests → more risk) this merits more thoughts Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Status of Spares : LHC Injectors ~ 3300 “warm” magnets, 250 different types Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Status of Spares : inventory Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Status of Spares for protons : priorities Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Status of Spares for ions : priorities Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What still needs more understanding Ø Why regular inter-turn short circuits in the SPS? Ø How many PS bus bars are wet/potentially weak? Ø How critical is water erosion in the SPS magnets? Ø Where else we have water erosion? Ø Can we monitor water erosion? Ø How critical is mechanical fatigue, in particular in the SPS? Ø Can we identify the weakest magnets? Ø Till which point shall we test? Ø What are the magnets requiring the development of tools to speed-up their possible replacement in case of failure? Ø How dealing with very radioactive magnets (LHC points 3 -7)? Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What we are going to do Ø Analyze the mechanisms of SPS inter-turn short circuits Ø Experiment new dielectric tests for the PS bus bars Ø Perform more detailed analysis on water erosion in the SPS Ø Design and set-up endoscopic tools to check water erosion Ø Design and implement inter-turn coil dielectric checks Ø Redefine test criteria capable of identify faults, to be performed compatibly with available time and number of available spares Ø Keep in mind any fault can be repaired, except (typically) inter-turn short circuits or too radioactive magnets/components Ø Continue the analysis of spares Ø Reinforce contacts with experts in other large research institutes Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What may be needed after understanding Ø Replace all (or most) PS bus bars Ø Replace all PFWs in the PS main units, eventually reinforce GI Ø Initiate a massive, general consolidation of the SPS magnets Ø Purchase more spares unlikely we may need to Ø replace the PS main coils (no inter-turn short circuits so far) Ø consolidate the PSB magnets (they are very robust) Ø deal with generalized water erosion elasewhere than in the SPS however Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Failures of electrical machines is a complex science Ageing is only one of the mechanisms triggering failures Not always failures have precursors during normal operation monitoring analyze test … test analyze understand decide Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

What is needed now PS Complete and reinforce all spare bus bars sets (2 sets are missing, give priority). No need to decide now about a generalized replacement No need to decide now about a systematic replacement of PFWs or other parts in the main units SPS Main Units Design a definitive fix for the weakening pole shims Spares TBH and BHZ 20 are essential and have been funded Proton lines : desirable manufacture of TT 10 lattice quadrupoles and SPS sextupoles Ion lines : many spares missing, a decision about spares policy is needed New projects: attention to keep enough spares when operational magnets are used North Experimental Area Continue in the consolidation of the documentation Situation of signal and power cables to be assessed East Experimental Area A layout with reliable magnets has been identified, do not wait ! profit of other’s experience Autumn 2010 : international review of the LHC injectors magnets Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Importance of the yearly shutdown Example in the PS Visual inspection (on all machines): What was found: Water leaks on TT 2 magnets: QFO. 215, PS aux. Magnets: 205 in SS 13 and SS 14 PS Auxiliary Magnets: Magnet type 210 in SS 35 equipped with soft plumbing ! Oxydised connection on Magnet type 205 in SS 25 Soldered hydraulic connection magnet type 206 in SS 53 ! Degraded interlock wire insulation on magnet 802 -409 -802 No interlocks of the fast pulsed magnets Measurements: HV tests on the PS Main Magnets (Main coils 7 k. V, PFW 3 k. V + coil to coil 2 k. V, F 8 W 3 k. V) Contact resistance of the old PFW (25 units) Circuit resistance of the F 8 W on all magnets Shimming of the laminations Evolution of the contact resistance of a faulty contact measured at the max rms current of 80 A Inspection of moving laminations shimmed by glued vetresite plates Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

PSB Magnets 30% field increase shutdown BR. BHZ Normal configuration FIELD STRENGTH (T) PEAK CURRENT (A) Inner Rings Outer Rings POWER COMSUMPTION (k. W) Q (@ DT= 28 K) (l/min) DT (@ Q = 26 l/min) (K) Present +30% 0. 86 1. 12 4032 4065 49 26 28 5255 5515 83 44 47 study performed by Antony Newborough Davide Tommasini Ongoing consolidation of magnets BR. QF FIELD GRADIENT (T/m) PEAK CURRENT (A) POWER COMS. (k. W) Q (@ DT= 20 K) (l/min) DT (@ Q = 12 l/min) (K) PRESENT 5. 60 4032 16 12 20 +%30 7. 66 5255 27 20 34 BR. QD FIELD GRADIENT (T/m) PEAK CURRENT (A) POWER COMS. (k. W) Q (@ DT= 20 K) (l/min) DT (@ Q = 8. 3 l/min) (K) PRESENT 5. 60 4032 11 8 20 +%30 7. 66 5255 19 14 34 IEFC Workshop February 10 th , 2010

NORMAWEB http: //norma-db. web. cern. ch/cern_norma/general/ Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010

Conclusions Ø Magnets in the CERN accelerators are impressively reliable Ø The PSB and the PS are the most reliable accelerators at CERN Ø No reasons to think the oldest accelerators are close to end of life Ø We need to ensure we have a sufficient number of spares Ø We need to ensure we can effectively treat any magnet at any location Ø We need more understanding of the real status of these magnets Ø Do not forget to define responsibility for the main supply cables Keep regular maintenance Improve diagnostics Be careful with spare policy 4 -weeks of shutdown needed Davide Tommasini Ongoing consolidation of magnets IEFC Workshop February 10 th , 2010